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New optical area sensor technologies have made
it possible to acquire millions of points simultaneously on complex free-form
surfaces in the time it would previously have taken to measure a single point
[5,6]. This opens up the possibility of rapid, on-line measuring the entire
surface of cars, components, stamping tools and dies. Coordinate measurement
machines (CMMs) are typically equipped with touch probes for dimensional
inspection, but can potentially be retrofitted with area sensors to drastically
increase their data acquisition throughput, thereby reducing inspection time.
Additionally, area sensing would allow CMMs to expend beyond their traditional
role of dimension inspection into a much boarder realm of quality control
involving, for instance, sheet metal surface quality and highlights. This would
lead to reduced quality inspection cost and timing, and ultimately improved
customer satisfaction.

Sensor planning is a critical step in operating a CMM to acquire
intended data. With touch probes, the number of points to locate on a part is
limited and planning is done by hand in what is known as a
"Click-and-Check" fashion. This is currently the only method
available in commercial software for sensor planning. The CAD model is
visualized in a graphics system. The user interface allows the user to
"click" and insert locations on the part to be inspected. Animation
can be performed such that collisions or in feasible kinematics conditions are
revealed and corrected by the operator. This process is repeated for all points
of interest.

Path planning for robotically manipulated area sensors presents
unique challenges not found in typical path planning operations, including:
glare, visibility, focus, stand-off/field-of-view, resolution,
and margin of area overlap. Because there are a large number of factors to be
considered simultaneously, it is very difficult for a human to do this path
planning manually. In addition, the number of viewpoints to plan for the sensor
might be very large due to size of the part surface and the required data
resolution.

Hence
it was the first objective of this work to automate the sensor path planning task for a CMM equipped with an optical area sensor. It
was the second objective of this work to develop a seamless dataflow that
starts from the CAD model of a part to be inspected and ends with a color map
showing the deviation of the part from the CAD model. It was the third objective
of this work to develop a complete task flow in achieving the CMM-based optical
area sensing. It was the ftheth objective of this work to apply this technology
to a range of applications, including, but not limited to, metrology, spray
painting, and chopper gun trajectory planning.

The overall concept of the work is illustrated in Figure
1. The internal performance requirement for such a
system is shown in Figure
2. Th...